Silicon battery and method for assembly

ABSTRACT

A method for forming a battery anode can include: forming a slurry including active material comprising silicon particles, wherein the silicon particles can be derived from silica fumes, depositing the slurry on an current collector, drying the deposited slurry to form a deposited film, and compacting the deposited film to form the battery anode.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 63/254,868, filed 12-OCT-2021 and U.S. Provisional Application No. 63/273,043, filed 28-OCT-2021, each of which is incorporated in its entirety by this reference.

TECHNICAL FIELD

This invention relates generally to the battery field, and more specifically to a new and useful system and method in the battery field.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a schematic representation of the method.

FIG. 2 is a schematic representation of an example of preparing an electrode.

FIG. 3 is a schematic representation of an example of a roll to roll process.

FIG. 4A is a schematic representation of an example of a pouch cell that includes tabs.

FIG. 4B is a schematic representation of an example of a tab-less pouch cell.

FIG. 5 is a schematic representation of a battery cell assembly process.

FIGS. 6A, 6B, and 6C are schematic representations of exemplary electrodes with different tab configurations.

FIGS. 7A-7F are schematic representations of exemplary silicon particles.

FIGS. 8A-8E are scanning electron micrographs of exemplary silicon particles.

FIGS. 9A-9C are scanning electron micrographs of exemplary silicon anode films with no calendering, 50% calendering (e.g., densification, compaction, etc.), and 30% calendering (e.g., densification, compaction, etc.) respectively.

FIGS. 10A-10C are scanning electron micrographs of exemplary silicon anode films with non-milled silicon particles, milled (e.g., cold welded) silicon particles without milling the graphite particles, and milled (e.g., cold welded) silicon particles milled graphite particles respectively.

FIG. 11 is a scanning electron micrograph of an exemplary silicon anode film that includes silicon particles and C65 carbon black (e.g., the silicon anode does not include graphite).

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following description of the preferred embodiments of the invention is not intended to limit the invention to these preferred embodiments, but rather to enable any person skilled in the art to make and use this invention.

1. Overview

As shown for example in FIG. 1 , a method for manufacturing a battery can include: receiving an electrode material S100; forming an electrode S200; assembling a battery cell S300; optionally, conditioning the battery cell S400; optionally, assessing a quality of the battery S500 (e.g., battery cell, battery pack, etc.); and/or any suitable steps. The battery cell preferably includes an anode, a cathode, a separator, a housing, and an electrolyte; but can additionally or alternatively include any suitable components.

2. Benefits

Variations of the technology can confer several benefits and/or advantages.

First, variants of the technology can enable drop-in functionality for preparing battery including silicon in the anode. For example, a silicon anode material can be used in place of, combined with, and/or in addition to a carbon anode material in the battery manufacture, by including the silicon in a common slurry with the graphite (e.g., without additional processing steps).

However, variants of the technology can confer any other suitable benefits and/or advantages.

As used herein, “substantially” or other words of approximation (e.g., “about,” “approximately,” etc.) can be within a predetermined error threshold or tolerance of a metric, component, or other reference (e.g., within 0.001%, 0.01%, 0.1%, 1%, 5%, 10%, 20%, 30%, etc. of a reference), or be otherwise interpreted.

3. Battery

The battery system 100 preferably functions to generate or produce electrical power and/or provide or supply the electrical power to one or more loads (e.g., which can function to consume the electrical power such as to convert it into another form of energy). The battery system is preferably a secondary cell (e.g., a rechargeable battery system such as one where each electrode can operate as an anode 120 or cathode 110), but can additionally or alternatively form primary cells, bipolar cells, and/or any suitable battery cell. The battery system is preferably operated (e.g., cycled) between about 2.5 V and 5 V (and/or a range contained therein such as 2.5-4.2 V, 2.7 V-4.2 V, 2.5-4 V, 2.7-3.8 V, 2.7-4.3 V, etc.), but can be cycled between any suitable voltages (e.g., less than 2.5 V or greater than 5 V). In some variants, limiting the range of operation voltages can improve the stability and/or longevity (e.g., number of cycles before significant degradation occurs, number of cycles before critical battery failure, etc.) of the battery system. The voltage range that the battery system can be operated over can depend on the electrode materials, the electrode capacities, the electrode thicknesses, the load, a programmed (or otherwise specified) voltage range, and/or any suitable properties.

The components of the system can be solid-state, fluid-state (e.g., liquid, plasma, gas, etc.), gel-state, a combination of states (e.g., at a critical point, a mixed state, one component in a first state and another component in a second state, etc.), and/or have any suitable state of matter. The resultant battery can have a solid state build, Li metal build (e.g., lithium-ion or lithium polymer batteries), metal-air build (e.g., silicon-air battery), and/or any other suitable construction. The resultant battery can be rigid, flexible, and/or have any other suitable stiffness (e.g., wherein component thicknesses, numerosity, flexibility, rigidity, state of matter, elasticity, etc. can be selected to achieve the desired stiffness). The resultant battery can be a pouch cell, a cylindrical cell, a prismatic cell, and/or have any other suitable form factor.

The electrodes preferably function to generate ions (e.g., electrons) and to make contact to other parts of a circuit (e.g., a load). The battery system preferably includes at least two electrodes (e.g., an anode and a cathode), but can include any number of electrodes. The number of cathodes and anodes can be equal, there can be more anodes than cathodes, or there can be more cathodes than anodes. For example, the battery can include 1, 2, 3, 4, 5, 6, 10, 20, 50, 100, values or ranges therebetween, and/or any other suitable number of anodes and/or cathodes. The anodes and/or cathodes can be single-sided, double sided, and/or otherwise configured. When the battery includes multiple anodes and/or cathodes, the anodes and cathodes are preferably interleaved (e.g., alternate in the electrode stack); alternatively, the cathodes and/or anodes can be grouped or stacked together and/or can otherwise be arranged (e.g., a single cathode can be surrounded by a plurality of anodes dictated by a cell geometry). Each anode of the plurality of anodes can be the same (e.g., same materials, same physical properties within specification tolerances, same electrical properties, etc.) or different (e.g., different materials, different physical properties, different electrical properties, etc.). Each cathode of the plurality of cathodes can be the same (e.g., same materials, same physical properties within specification tolerances, same electrical properties, etc.) or different (e.g., different materials, different physical properties, different electrical properties, etc.).

Each electrode is preferably in contact with a collector (e.g., charge collector, electron collector, hole collector, etc.), which can functions to collect and transport charged particles (e.g., electrons). The collector can be different or the same for each electrode. The collector is preferably electrically conductive, but can be semiconducting and/or have any suitable conductivity. The collector can be a wire, a plate, a foil, a mesh, a foam, an etched material, a coated material, and/or have any morphology. Example collector materials include: aluminium, copper, nickel, titanium, stainless steel, carbonaceous materials (e.g., carbon nanotubes, graphite, graphene, etc.), brass, polymers (e.g., conductive polymers such as PPy, PANi, polythiophene, etc.), combinations thereof, and/or any suitable material. The electrode is typically deposited on the collector. However, additionally or alternatively the collector can be fastened to, adhered to, soldered to, integrated with (e.g., coextensive with a substrate of), and/or can otherwise be interfaced with the electrode.

Each electrode can be a layered material (e.g., alternating stacks of materials such as an active anode that alternates between carbonaceous material and silicon material), a coextensive material (e.g., active material can be a substantially homogeneous mixture of components), thin films (e.g., 1 nm to 100 µm thick and/or any values or subranges therein), thick films (e.g., >100 µm thick), and/or have any suitable morphology.

Each electrode thickness can be any suitable value or range thereof between about 1 µm and 1 cm (such as 1 µm, 2 µm, 5 µm, 10 µm, 20 µm, 50 µm, 100 µm, 200 µm, 500 µm, 1 mm, 2 mm, 5 mm, 1 cm), a thickness less than 1 µm, and/or a thickness greater than 1 cm. The thickness of each layer can be the same and/or different. For example, an anode can have a thickness approximately equal to 0.1×, 0.2×, 0.5×, 0.8×, 0.9×, 1×, 1.05×, 1.1×, 1.2×, 1.5×, 2×, 2.1×, 2.2×, 2.5×, 3×, 5×, 10×, or values therebetween of the cathode thickness. In a variation on this example, these ratios can relate the capacity of the anode to the cathode (e.g., an anode thickness can be determined to have a thickness that will match an anode capacity to a ratio of the cathode capacity such as in units of mAh/cm²). Having a thicker anode (e.g., thicker than necessary to match a cathode capacity) can be beneficial, for example, because as the cathode transfers material to the anode (e.g., during discharging), the anode may not expand by as much as when the anode and cathode have matching capacities. This benefit can be enabled, for instance, by using an anode material with a large capacity (such as silicon). However, a thicker anode can otherwise be beneficial and/or be enabled.

The N/P ratio (e.g., a capacity ratio such as a linear capacity, an areal capacity, volumetric capacity, total capacity, etc. of the anode to the cathode) is preferably between about 0.5-2 (e.g., 0.5, 0.6, 0.75, 0.9, 1, 1.05, 1.1, 1.15, 1.2, 1.25, 1.3, 1.35, 1.4, 1.45, 1.5, 1.6, 1.7, 1.75, 1.8, 1.9, 2, values or ranged therebetween, etc.), but can be less than 0.5 or greater than 2. A larger N/P ratio can be beneficial for increasing the stability of the anode (e.g., because the anode will be less lithiated and undergo less volume expansion compared to a battery with a smaller N/P ratio). The N/P ratio (e.g., an optimal N/P ratio) can be selected based on the anode material (or properties thereof such as particle or grain size, external expansion coefficient, etc.), cathode material (or properties thereof), battery stability (e.g., a target stability), battery cycles (e.g., a target number of cycles, minimum number of cycles, etc.), energy density, voltage range, electrode thickness, temperature, cell variation, number of layers, electrolyte composition, and/or can otherwise be selected or tuned.

Each electrode can have a single active surface, two active surfaces (e.g., a top and a bottom surface), be active around all or any portion of the exposed surface, and/or have any suitable number of active surfaces, where active surfaces can refer to a surface coupled (e.g., via electrolyte) to another electrode, to an external load (e.g., via a collector), and/or otherwise be defined.

Each electrode preferably has approximately the same capacity (e.g., within ±1%, ±2%, ±5%, ±10%, ±20%, etc.). However, electrodes can have different capacities. For example, an anode can have a capacity approximately equal to 0.1×, 0.2×, 0.5×, 0.8×, 0.9×, 1×, 1.05×, 1.1×, 1.2×, 1.5×, 2×, 2.1×, 2.2×, 2.5×, 3×, 5×, 10×, and/or values therebetween of the cathode capacity (for example, in units of mAh/cm²). However, the anode can have a capacity less than 0.1× or greater than 10× the cathode capacity. Having anodes with capacities greater than the cathode can be beneficial for modifying (e.g., improving) a stability of the anode, modifying (e.g., controlling) an expansion of the anode, modifying (e.g., decreasing) an amount of anode plating from the cathode, and/or can otherwise be beneficial. Each electrode capacity can be controlled or modified based on an electrode thickness, an electrode material, an electrode doping, an electrolyte, an electrode doping, an electrode morphology (e.g., porosity, pore volume, pore distribution, etc.), an electrode substrate, and/or any suitable properties.

The electrode substrate (e.g., collector) is preferably a metal (e.g., aluminium, copper, silver, gold, nickel, alloys thereof or incorporating the aforementioned elements, etc.), but can additionally or alternatively include carbonaceous substrates and/or any suitable substrate(s). The substrate thickness is preferably between about 5-20 µm. However, the substrate thickness can be greater than 20 µm or less than 5 µm. In an illustrative example, an anode substrate can be a 9-16 µm thick copper foil. In a second illustrative example, a cathode substrate can be a 9-20 µm thick aluminium foil. However, any substrate can be used.

3.1 Cathode

The cathode material preferably includes lithium, but can additionally or alternatively include any suitable cathode materials. Examples of lithium containing cathode materials include: lithium cobalt oxide (LCO), lithium nickel manganese cobalt oxide (NMC), lithium nickel manganese oxide (LNMO), lithium iron phosphate (LFP), lithium manganese oxide (LMO), lithium nickel cobalt aluminium oxide (NCA), and/or any suitable cathode materials. However, any suitable lithium cathode and/or other cathode material can be used.

3.2 Anode

The anode material can include: active material, binder, conductive material, and/or any suitable material(s).

Active material of the anode preferably includes silicon material, but can additionally or alternatively include carbonaceous material and/or any suitable anode material. The active material is preferably a substantially homogeneous mixture of components, but can be a heterogeneous mixture of components.

The silicon material 124 preferably includes silicon particles 125 (e.g., porous particles, solid particles, nanoparticles, meso particle, microparticles, macroparticles, etc.), but can include films and/or any suitable structure. In variants, the particles can form clusters (e.g., aggregates), agglomers (e.g., agglomerates, clusters of clusters, etc.), and/or can have any suitable form.

The particles are preferably made of silicon, but can additionally or alternatively include silica (e.g., silicon oxide such as SiO_(x), SiO₂, etc.), and/or any suitable additives or other materials or elements. The silicon content of the silicon material is preferably at least 50% (e.g., 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, 99%, 99.5%, 99.9%, 99.99%, values therebetween, >99.99% such as by weight, by volume, by stoichiometric ratio, etc.), but can be less than 50% (e.g., can include regions with less than 50% silicon such as carbon rich regions). The remainder of the silicon content can include oxygen, nitrogen, hydrogen, carbon, magnesium, aluminium, lithium, sodium, halogens, and/or any suitable elements. For example, the elemental composition of the silicon material can include SiOC, SiC, Si_(x)O_(x)C, Si_(x)O_(x)C_(x), Si_(x)C_(x), SiO_(x), Si_(x)O_(x), SiO₂C, SiO₂Cx, SiOC_(Y), SiC_(Y), Si_(x)O_(x)C_(Y), Si_(x)O_(x)C_(x)Y_(x), Si_(x)C_(x)Y_(x), SiO_(x)Y_(x), Si_(x)O_(x)Y_(x), SiO₂CY, SiO₂C_(x)Y_(x), and/or have any suitable composition (e.g., include additional element(s)), where Y can refer to any suitable element of the periodic table (e.g., halgoens, chalcogens, pnictogens, group 13 elements, transition metals, alkaline earth metals, alkali metals, etc.) and x is preferably between 0.001 and 0.05 (but can be less than 0.001 or greater than 0.05). The material composition of the silicon material can be isotropic (e.g., homogeneous distribution of silicon and other additives, dopants, impurities, etc.) and/or anisotropic (e.g., inhomogeneously distributed silicon and other materials such as forming a core-shell like structure). In an illustrative example of an anisotropic material distribution, a surface of the silicon material (e.g., a surface exposed to atmosphere or an environment proximal the silicon material) can have a higher oxygen or silica concentration than an interior of the silicon material (e.g., a volume that is not proximal or exposed to the atmosphere or environment). However, an engineered material gradient and/or any suitable material distribution can exist within the silicon material.

In some variants, the silicon material can include carbon. For example, the silicon material can be coated with carbon; form a composite, alloy, compound (e.g., silicon carbide), material, and/or other chemical species with carbon; and/or can otherwise include carbon. The carbon can be homogeneous distributed or inhomogeneously distributed (e.g., forming one or more carbon rich and/or carbon poor grains, forming carbon clusters, etc.). In these variants, the total carbon content (e.g., by weight, by volume, by stoichiometric ratio, etc.) can be between 1-99% (e.g., where the remainder can include silicon and/or any suitable trace elements) by weight, by volume, by stoichiometry, and/or according to any suitable reference. However, the carbon content can be less than 1% or greater than 99%. In a first specific example, a silicon material can include at least 50% silicon, and between 1-45% carbon, where the percentages can refer to a mass percentage of each component. In this specific example, the silicon material can include at most about 5% oxygen. In a second specific example, a silicon material can include approximately 85-93% silicon, approximately 2-10% carbon, and approximately 5-10% oxygen, where the percentages can refer to a mass percentage of each component. However, the silicon particles can include any suitable carbon composition.

The shape of the particles can be spheroidal (e.g., spherical, ellipsoidal, as shown for example in FIG. 7A, FIG. 7C, FIG. 7F, FIG. 8E, etc.); rod; platelet; star; pillar; bar; chain; flower; reef; whisker; fiber; box; polyhedral (e.g., cube, rectangular prism, triangular prism, frustopyramidal, as shown for example in FIG. 7E or FIG. 8C, etc.); frustoconical, have a worm-like morphology (e.g., vermiform; as shown for example in FIG. 7B, FIG. 8A, or FIG. 8B; etc.); have a foam like morphology; have an egg-shell morphology; have a shard-like morphology (e.g., as shown for example in FIG. 7D or FIG. 8D); include one or more straight edges (e.g., meeting at rounded corners, at sharp corners, etc. as shown for example in FIG. 1E, FIG. 5A, FIG. 5B, FIG. 5C, FIG. 9A, etc.) and/or have any suitable morphology.

The particles can be freestanding, clustered, aggregated, agglomerated, interconnected, and/or have any suitable relation or connection(s). As an illustrative example (as shown for instance in FIG. 8C or FIG. 10B), a silicon material can include a plurality of fused particles (e.g., clusters, agglomers, agglomerates, etc.), where each fused particle includes a plurality of individual particles that have fused (e.g., been cold welded) together (e.g., without substantially changing a morphology of the underlying particles, by melding the underlying particles at points of intersection, by fusing or sealing a surface of the fused particle and retaining a surface area of the unfused particles, etc.; with a change in the morphology of the individual particles; etc.).

A characteristic size of the particles is preferably between about 1 nm to about 10000 nm such as 2 nm, 5 nm, 10 nm, 20 nm, 25 nm, 30 nm, 50 nm, 75 nm, 100 nm, 125 nm, 150 nm, 175 nm, 200 nm, 250 nm, 300 nm, 400 nm, 500 nm, 1000 nm, 1500 nm, 2000 nm, 2500 nm, 3000 nm, 4000 nm, 5000 nm, 6000 nm, 7500 nm, 8000 nm, 9000 nm, 9500 nm, 10000 nm, values or ranges therebetween, etc.). However, the characteristic size can additionally or alternatively be less than about 1 nm and/or greater than about 10000 nm. For example, a fused particle and/or cluster (e.g., aggregate) of silicon particles can have a characteristic size between about 1 µm and 10 µm (e.g., 1-3 µm, 3-5 µm, 5-10 µm, 3-10 µm, 3-7 µm, 1-5 µm, 1-7 µm, 0.9-3 µm, 8-12 µm, other values or ranges therein, etc.), and the particles that make up the fused particle and/or cluster can have a characteristic size between about 2 and 500 nm (e.g., 1-10 nm, 10-50 nm, 10-100 nm, 20-200 nm, 50-500 nm, 50-525 nm, 10-550 nm, 100-500 nm, values or ranges therein, etc.). In variations of this example, the fused particle and/or clusters can form tertiary structures (e.g., agglomerates, agglomers, etc.) which can have a characteristic size between about 5-100 µm.

The characteristic size can include the radius, diameter, circumference, longest dimension, shortest dimension, length, width, height, pore size, a shell thickness, and/or any size or dimension of the particle. The characteristic size of the particles is preferably distributed on a size distribution (e.g., where the characteristic size can uniquely define the distribution; can be a moment of the distribution; can be associated with specific percentiles of the distribution such as the D10, D20, D50, D60, D80, D90, etc. size; etc.). The size distribution can be a substantially uniform distribution (e.g., a box distribution, a mollified uniform distribution, etc. such that the number of particles or the number density of particles with a given characteristic size is approximately constant), a Weibull distribution, a normal distribution, a log-normal distribution, a Lorentzian distribution, a Voigt distribution, a log-hyperbolic distribution, a triangular distribution, a log-Laplace distribution, and/or any suitable distribution. The characteristic size distribution of the particles (particularly, but not exclusively for fused particles) is preferably narrow (e.g., standard deviation is less than about 20% of a mean of the size distribution), but can be broad (e.g., a standard deviation greater than about 20% of a mean of the size distribution), and/or can otherwise be characterized. A narrow characteristic size distribution can provide a technical advantage of enhancing a lifetime and/or stability of the silicon material as some undesirable processes depend on a size of the silicon material (and having more uniform size such as with a narrow distribution can lead to more uniform degradation within the sample).

The characteristic size (and its associated distributions) are typically determined directly (e.g., by directly imaging the silicon material such as using scanning electron microscopy, transmission electron microscopy, scanning transmission microscopy, etc.), but can be determined indirectly (e.g., based on scattering experiments such as dynamic light scattering; based on optical properties such as bandgap energy, bandgap width, etc.; based on x-ray scattering such as based on a width of x-ray scattering; etc.), and/or can otherwise be determined.

The particles can be solid, hollow, porous, as shown for example in FIGS. 7A-7F or FIGS. 8A-8E, and/or have any structure.

The silicon material can be crystalline, amorphous, nanocrystalline, protocrystalline, and/or have any suitable crystallinity. When the silicon material (e.g., particles thereof) include crystalline regions, the silicon material is preferably polycrystalline, which can provide a technical advantage of accommodating mechanical or other stresses that the silicon material undergo. However, the silicon material can be monocrystalline. In some examples, the silicon particles can include crystalline regions and non-crystalline regions (e.g., amorphous regions).

The exterior surface of the silicon material is preferably substantially sealed (e.g., hinders or prevents an external environment from penetrating the exterior surface). However, the exterior surface can be partially sealed (e.g., allows an external environment to penetrate the surface at a predetermined rate, allows one or more species from the external environment to penetrate the surface, etc.) and/or be open (e.g., porous, include through holes, etc.). The exterior surface can be defined by a thickness or depth of the silicon material. The thickness is preferably between about 1 nm and 10 µm (such as 1 nm, 2 nm, 3 nm, 5 nm, 10 nm, 20 nm, 50 nm, 100 nm, 200 nm, 500 nm, 1 µm, 2 µm, 5 µm, 10 µm, values therebetween), but can be less than 1 nm or greater than 10 µm. The thickness can be homogeneous (e.g., approximately the same around the exterior surface) or inhomogeneous (e.g., differ around the exterior surface).

In specific examples, the exterior surface can be welded, fused, melted (and resolidified), and/or have any morphology. For example, the silicon particles can be cold welded (e.g., as disclosed in U.S. Pat. Application 17/824,627 titled ‘SILICON MATERIAL AND METHOD OF MANUFACTURE’ filed 25-MAY-2022, which is incorporated in its entirety by this reference).

The (specific) surface area of the exterior surface of the silicon material is preferably small (e.g., less than about 0.01, 0.5 m²/g, 1 m²/g, 2 m²/g, 3 m²/g, 5 m²/g, 10 m²/g, 15 m²/g, 20 m²/g, 25 m²/g, 30 m²/g, 50 m²/g, values or between a range thereof), but can be large (e.g., greater than 10 m²/g, 15 m²/g, 20 m²/g, 25 m²/g, 30 m²/g, 50 m²/g, 75 m²/g, 100 m²/g, 110 m²/g, 125 m²/g, 150 m²/g, 175 m²/g, 200 m²/g, 300 m²/g, 400 m²/g, 500 m²/g, 750 m²/g, 1000 m²/g, 1250 m²/g, 1400 m²/g, ranges or values therebetween, >1400 m²/g) and/or any suitable value.

The (specific) surface area of the interior of the silicon material (e.g., a surface exposed to an internal environment that is separated from with an external environment by the exterior surface, a surface exposed to an internal environment that is in fluid communication with an external environment across the exterior surface, interior surface, etc.) is preferably large (e.g., greater than 10 m²/g, 15 m²/g, 20 m²/g, 25 m²/g, 30 m²/g, 50 m²/g, 75 m²/g, 100 m²/g, 110 m²/g, 125 m²/g, 150 m²/g, 175 m²/g, 200 m²/g, 300 m²/g, 400 m²/g, 500 m²/g, 750 m²/g, 1000 m²/g, 1250 m²/g, 1400 m²/g, ranges or values therebetween, >1400 m²/g), but can be small (e.g., less than about 0.01, 0.5 m²/g, 1 m²/g, 2 m²/g, 3 m²/g, 5 m²/g, 10 m²/g, 15 m²/g, 20 m²/g, 25 m²/g, 30 m²/g, 50 m²/g, values or between a range thereof). In some variations, the internal surface area can be less than a threshold surface area (e.g., 200 m²/g, 300 m²/g, 500 m²/g, 750 m²/g, 1000 m²/g, 1500 m²/g, 2000 m²/g, 5000 m²/g, etc.), which can provide a technical advantage of limiting oxidation of the silicon material prior to the formation of an external surface (e.g., with a lower surface area, sealed external surface, etc.). However, there need not be a threshold upper surface area (e.g., by controlling an environment to have less than a target oxygen concentration that can depend on the surface). However, the surface area of the interior can be above or below the values above, and/or be any suitable value.

In some variants, the surface area can refer to a Brunner-Emmett-Teller (BET) surface area. However, any definition, theory, and/or measurement of surface area can be used. The surface area can be determined, for example, based on calculation (e.g., based on particle shape, characteristic size, characteristic size distribution, etc. such as determined from particle imaging), adsorption (e.g., BET isotherm), gas permeability, mercury intrusion porosimetry, and/or using any suitable technique. In some variations, the surface area (e.g., an internal surface area) can be determined by etching the exterior surface of the material (e.g., chemical etching such as using nitric acid, hydrofluoric acid, potassium hydroxide, ethylenediamine pyrocatechol, tetramethylammonium hydroxide, etc.; plasma etching such as using carbon tetrafluoride, sulfur hexafluoride, nitrogen trifluoride, chlorine, dichlorodifluoromethane, etc. plasma; focused ion beam (FIB); etc.), by measuring the surface area of the material before fusing or forming an external surface, and/or can otherwise be determined. However, the surface area (and/or porosity) can be determined in any manner.

In some variations, the silicon material (e.g., silicon particles) can include a coating. The coating is preferably a carbonaceous coating (e.g., an inorganic carbon coating, polymer coating, etc.). However, any suitable coating can be used. The coating material can be the same as and/or different from the binder and/or conductive additive materials (e.g., where coating material is accounted for as a portion of the active materials in the anode). However, any suitable coating material can be used. As an illustrative example, silicon particles can be coated with polyacrylonitrile (e.g., PAN). A coating thickness is preferably 1-10 nm. However, the coating thickness can be less than 1 and/or greater than 10 nm,

In specific example, a silicon material can include a coating as disclosed in (e.g., a coated silicon material can be as disclosed in) U.S. Pat. Application No. 17/890,863 titled ‘SILICON MATERIAL AND METHOD OF MANUFACTURE’ filed 18-AUG-2022, which is incorporated in its entirety by this reference.

The silicon material preferably has a small external expansion (e.g., less than about 30% external expansion, less than 15%, 0% external expansion, compression, etc.), where the external expansion can be a volumetric, areal, linear, and/or other expansion (e.g., in response to temperature changes, in response to swelling due to chemicals, in response to lithiation, etc.). However, the silicon material can have any suitable external expansion.

In some variations, the silicon material can be a material as disclosed in U.S. Pat. Application No. 17/525,769 titled ‘SILICON MATERIAL AND METHOD OF MANUFACTURE’ and filed 12-NOV-2021, PCT Publication Number WO2022104143 titled ‘METHOD OF MANUFACTURE OF POROUS SILICON’ and filed 12-NOV-2021, U.S. Pat. Application No. 17/841,435 titled ‘SILICON MATERIAL AND METHOD OF MANUFACTURE’ and filed 15-JUN-2022, U.S. Application No. 17/824,627 titled ‘SILICON MATERIAL AND METHOD OF MANUFACTURE’ filed 25-MAY-2022, U.S. Application No. 17/890,863 titled ‘SILICON MATERIAL AND METHOD OF MANUFACTURE’ filed on 18-AUG-2022, each of which is incorporated in its entirety by this reference. However, any suitable material can be used.

Carbonaceous material of the active material preferably contributes to the capacity of the active material. However, the carbonaceous material be a noncontributor to the capacity. The carbonaceous material is preferably graphitic material (e.g., graphite, graphene, carbon nanotubes, carbon nanoribbons, carbon quantum dots, etc.). However, additionally or alternatively, any suitable carbonaceous material can be included.

The graphitic material 126 preferably includes graphite particles 127. However, additionally or alternatively, graphite films, graphite sheets, shards, and/or can have any suitable morphology. The graphite particles are preferably spheroidal (e.g., with a sphericity greater than about 0.95). However, the graphite particles can additionally or alternatively be ellipsoidal, fiber-shaped, irregular-shape, polyhedral, and/or can have any suitable shape. A characteristic size (e.g., diameter, radius, circumference, largest aspect, shortest aspect, etc. where the characteristic size can refer to a mean size, D10, D90, D25, D75, etc. of a particle size distribution) of the graphite particles is preferably between about 10 µm and 50 µm. However, the characteristic size can be less than 10 µm and/or greater than 50 µm. In some variants, the graphitic particles can be broken into shard like morphologies (e.g., by milling, comminution, etc.) as shown for example in FIG. 10B or FIG. 10C.

In a first specific example, the active material can include about 30-50% silicon particles and/or silicon materials (e.g., by mass, by volume, by stoichiometry, by particle count, etc.) and about 50-70% graphitic material (e.g., by mass, by volume, by stoichiometry, by particle count, etc.). In a second specific example (as shown for instance in FIG. 11 ), the active material can be composed essentially of (e.g., 99%, 99.9%, 99.95%, 99.99%, etc.) silicon particles. However, the active material can include any suitable amount of silicon particles (and/or silicon materials such as 10-90% by mass, volume, stoichiometry, particle count, etc.), graphitic material (e.g., graphite particles; such as 10-90% by mass, volume, stoichiometry, particle count, etc.), and/or any suitable components.

The binder 129 can functions to secure (e.g., adhere) the electrode to the substrate and/or a housing (e.g., case) of the battery system, secure (e.g., bond, adhere, laminate, etc. such as to maintain electrical contact between, a threshold spacing between, etc.) active material together (e.g., adhere silicon particles to other silicon particles, adhere silicon particles to graphitic particles, etc.), and/or can otherwise function. The binder can be electrically insulating, electrically conductive, semiconducting, and/or have any suitable electrical conductivity. Examples of binders include: carboxymethyl cellulose (CMC), styrene-butadiene rubber (SBR), poly(acrylic acid) (PAA), sodium alginate (SA), polyvinylidene fluoride (PVDF), polyaniline (PANI), poly(9,9-dioctylfluorene-cofluorenone-co-methyl benzoic ester) (PFM), polytetrafluoroethylene (PTFE), poly(ethylene oxide) (PEO), polyvinyl alcohol (PVA), polyacrylonitrile (PAN), sodium carboxymethyl chitosan (CCTS), poly(3,4-ethylenedioxythiophene) polystyrene sulfonate (PEDOT:PSS), 3,4-propylenedioxythiophene (ProDOT), dopamine hydrochloride, polyrotaxanes, polythiophene, combinations thereof, and/or any suitable binder. In an illustrative example, an approximately 1:1 mixture (by mass, by volume, by stoichiometry, etc.) of SBR to CMC can be used as a binder. In some variations, the binder can be a coating of the silicon particles and/or graphitic particles.

The conductive material 128 can function to modify an electrical conductivity of the electrode (e.g., to ensure that the electrode has at least a threshold electrical conductivity, to ensure that the electrode has at most a threshold electrical conductivity, to ensure that the active material is electrically connected to the collector throughout the electrode, etc.). Examples of conductive materials include: carbon super P, acetylene black, carbon black (e.g., C45, C65, etc.), mesocarbon microbeads (MCMB), graphene, carbon nanotubes (CNTs) (e.g., single walled carbon nanotubes, multiwalled carbon nanotubes, semi-conducting carbon nanotubes, metallic carbon nanotubes, etc.), reduced graphene oxide, graphite, fullerenes, conductive polymers, combinations thereof, and/or any suitable material(s).

In a specific example of an anode composition, the anode can include about 70% (by mass, by volume, by stoichiometry, etc.) active material, about 20% (by mass, by volume, by stoichiometry, etc.) conductive material, and about 10% (by mass, by volume, by stoichiometry, etc.) binder. In a second specific example of an anode composition, the anode can include about 60-95% (by mass, by volume, by stoichiometry, etc.) active material, about 0-20% (by mass, by volume, by stoichiometry, etc.) conductive material, and about 0-20% (by mass, by volume, by stoichiometry, etc.) binder (including any suitable range or combination contained therein). However, the anode can include any suitable material(s) and/or composition.

3.3 Separator

The separator 130 preferably functions to hinder, slow, or prevent an anode and cathode from electrically contacting one another (thereby shorting the battery) while allowing ions (e.g., lithium cations) to pass through the separator. The separator is preferably flexible, but can be rigid and/or have any suitable mechanical property(s). The separator(s) are preferably ionically conductive, but can be ionically insulating, promote (or hinder) ion diffusion, and/or have any suitable ionic conductivity. The separator(s) can be permeable to electrolyte (e.g., be porous), can release electrolyte, can pump electrolyte, be solid, include through holes, be mesh, have unidirectional pathways, and/or can otherwise facilitate a (real, apparent, or effective) transfer of electrolyte from one side of the separator to the other. At least one separator is preferably arranged between each cathode/anode pair. However, the separator(s) can otherwise be arranged. The separator can be equidistant between the cathode and anode, closer to (e.g., proximal) the anode, or closer to (e.g., proximal) the cathode. However, the separator can otherwise be arranged. The separator preferably has a thickness between about 10 µm and 50 µm, but can be thinner than 10 µm or thicker than 50 µm.

The separator can be made of or include ceramics, gels, polymers, plastics, glass, wood, and/or any suitable materials. In some variants, a separator referred to as a “dry cell separator” can be used. Examples of separator materials include: polyolefin, polypropylene, polyethylene, combinations thereof (e.g., a mixture or blend of PP and PE), and/or any suitable separator material(s). In some variants, the separator can be a multi-layered separator. For instance, a polypropylene/polyethylene/polypropylene separator or a ceramic coated separator (e.g., ceramic coated PP, ceramic coated PE, ceramic coated PP/PE mixture, etc.) can be used. However, any suitable separator can be used.

In some variants, an ionic conductive polymer can be used as the separator and/or as an ionic conductive pathway (e.g., as electrolyte, as conductive material, etc.). The ionic conductive polymer can be mixed in and/or coat the anode and/or cathode and form an ionic conductive network throughout the cell. However, the ionic conductive polymer can otherwise be arranged.

3.4 Electrolyte

The electrolyte 140 preferably functions to electrically connect anode(s) to cathode(s) and enable or promote the movement of ions (but preferably not electrons) between the electrodes. However, the electrolyte can otherwise function. The electrolyte can be solid-phase, fluid phase (e.g., liquid-phase), and/or any suitable phase. For example, the electrolyte can be or include: a gel, a powder, a salt dissolved in a solvent, an acid, a base, a polymer, a ceramic, a salt (e.g., a molten salt), a plasma, ionic liquids, and/or have any suitable state or combination thereof of matter. The electrolyte can include organic materials, inorganic materials, and/or combinations thereof.

Examples of electrolytes (e.g., electrolyte salts), particularly but not exclusively for use with lithium ion batteries, include: lithium lanthanum titanates (e.g., Li_(0.34)La_(0.51)TiO_(2.94), Li_(0.75)La_(0.5)TiO₃, (Li_(0.33)La_(0.56))_(1.005)Ti_(0.99)Al_(0.01)O₃, etc.), lithium aluminium phosphates (e.g., Li_(1.3)Al_(0.3)Ti_(1.7)(PO₄)₃, Li_(1.5)Al_(0.5)Ge_(1.5)(PO₄)₃, etc.), lithium zirconates (e.g., Li₇La₃Zr₂O₁₂, Li_(6.55)La₃Zr₂Ga_(0.15)O₁₂, Li_(6.4)La₃ Zr₂Al_(0.2)O₁₂, etc.), lithium silicon phosphates (e.g., Li_(3.25)Si_(0.25)P_(0.75)O₄), lithium germanates (e.g., Li_(2.8)Zn_(0.6)GeO₄, Li_(3.6)Ge_(0.8)S_(0.2)O₄, etc.), lithium phosphorous oxynitrides (e.g., Li_(2.9)PO_(3.3)N_(0.46)), lithium phosphorous sulfides (e.g., Li₇P₃S₁₁, Li₁₀GeP₂S₁₂, Li_(3.25)Ge_(0.25)P_(0.75)S₄, Li_(3.4)Si_(0.4)P_(0.6)S₄, Li₃PS₄, etc.), lithium silicon phosphates (e.g., Li_(3.5)Si_(0.5)P_(0.5)O₄), lithium argyrodites (e.g., Li₆PS₅Br, LiPS₅Cl, Li₇PS₆, Li₆PS₅I, Li₆PO₅Cl, etc.), lithium nitrides (e.g., Li₃N, Li₇PN₄, LiSi₂N₃, etc.), lithium imide (e.g., Li₂NH), lithium borohydride (e.g., LiBH₄), lithium aluminium hydride (e.g., LiAlH₄), lithium amides (e.g., LiNH₂, Li₃(NH₂)₂I, etc.), lithium cadmium chloride (e.g., Li₂CdCl₄), lithium magnesium chloride (e.g., Li₂MgCl₄), lithium zinc iodide (e.g., Li₂ZnI₄), lithium cadmium iodide (e.g., Li₂CdI₄), lithium chlorate (e.g., LiClO₄), lithium bis(trifluoromethanesulfonyl)imide (e.g., LiC₂F₆NO₄S₂), lithium hexafluroarsenate (e.g., LiAsF₆), lithium hexaflurophosphate (e.g., LiPF₆), combinations thereof, and/or any suitable electrolytes (e.g., electrolyte salts, for instance replacing lithium with the appropriate ion associated with a cathode of the battery).

Examples of matrices (e.g., gels, hydrogels, polymers, solvents, etc.) can include: poly(ethylene oxide) (PEO), poly(vinylidene fluoride) (PVDF), polyacrylonitrile (PAN), poly(methyl methacrylate) (PMMA), ethylene carbonate (EC), diethyl carbonate (DEC), dimethyl carbonate (DMC), propylene carbonate (PC), polyethylene glycol (PEG), glycerol, water, combinations thereof, and/or any suitable matrix can be used. Typically, an electrolyte salt is dissolved in the matrix to a concentration between about 0.1 M and 10 M, but the concentration of the electrolyte salt can be less than 0.1 M or greater than 10 M.

In some examples, a mixture of inorganic and organic electrolytes can be used such as: Li_(6.4)La₃ Zr₂Al_(0.2)O₁₂ in PEO/LiTFSI, Li_(1.5)Al_(0.5)Ti_(1.5)(PO₄)₃ in PVDF/LiClO₄, or Li_(0.33)La_(0.557)TiO₃ in PAN/LiClO₄. However, any pure or combination of electrolytes can be used.

In some variants, the electrolyte can include one or more additives, which can function to facilitate (or hinder) the formation of the interfacial layer. Examples of additives include: vinylene carbonate (VC), fluoroethylene carbonate (FEC), propylene carbonate (and its derivatives), ammonium perfluorocaprylate (APC), vinyl ethylene carbonate (VEC), maleimides (e.g., ortho-phenylenedimaleimide, para-phenylenedimaleimide, meta-phenylenedimaleimide, etc.), glycolide, tetraoxaspiro[5,5]undecanes (TOS; such as 3,9-Divinyl-2,4,8,10-tetraoxaspiro[5,5]undecane), poly-ether modified siloxanes, combinations thereof, and/or other additives.

In some variants, the separator and electrolyte can be the same and/or integrated together. For example, the separator and/or the electrolyte can include a lithium ion conductive glass or ceramic material such as: lithium lanthanum titanate (LLTO; e.g., Li_(3x)La_(⅔-x)TiO₃ for o<x<⅔ such as x=0.11), lithium lanthanum zirconate (LLZO; e.g., Li₇La₃Zr₂O₁₂), lithium lanthanum zirconium tantalate (LLZTO; e.g., Li_(6.75)La₃Zr_(1.75)Ta_(0.25)O₁₂), lithium aluminium germanium phosphate (LAGP; e.g., Li_(1.5)Al_(0.5)G_(21.5)P₃O₁₂), lithium aluminium silicon phosphorous titanium oxide (LASPT; e.g., Li₂Al₂SiP₂TiO₁₃), combinations thereof, and/or any suitable materials. However, any suitable lithium-ion conductive glass or ceramic material can be used.

The battery system preferably includes a housing 140 (e.g., container), which functions to enclose the electrodes, electrolyte, separator, and/or collector. The housing can function to prevent shorting of the electrodes resulting from contact with objects in the external environment. The housing can be made of metal (e.g., steel, stainless steel, etc.), ceramics, plastic, wood, glass, and/or any suitable materials. Examples of housing shapes include round (e.g., coin, button, cylindrical, etc.), not round, flat (e.g., layer built, pouch, etc.), prismatic (e.g., square, rectangular, etc.), and/or any suitable shape. The housing is preferably electrically insulated from the electrodes. However, in some variations, the housing can be in electrical contact with one or more electrodes (e.g., or more anode in a battery that includes more than one anode, one or more cathode in a battery that includes more than one cathode, etc.).

The housing preferably includes two terminals (e.g., one positive and one negative), but can include more than two terminals (e.g., two or more positive terminals, two or more negative terminals), a single terminal, and/or any number of terminals. The terminals can function to connect the battery electrodes to a load. Examples of terminals include coiled terminals, spring terminals, plate terminals, and/or any suitable terminals.

The housing can be sealed using adhesive, fastener(s), connector(s), binder(s), physical seal, chemical seals, electromagnetic seals, and/or any suitable connectors or sealing mechanism.

In a specific example, a battery can include any suitable battery as disclosed in U.S. Pat. Application No. 17/672,532 titled ‘SILICON ANODE BATTERY’ filed 15-FEB-2022, which is incorporated in its entirety by this reference.

4. Method

The method can function to manufacture a battery (e.g., a battery as described above). The method can include: producing an electrode material S100, producing an electrode S200, assembling the battery S300, conditioning the battery S400, assessing the battery S500, and/or any suitable steps. The method and/or steps thereof can be performed in a single chamber (e.g., a furnace, an oven, etc.) and/or in a plurality of chambers (e.g., a different chamber for each step or substep, a heating chamber, a coating chamber, a milling chamber, a washing chamber, etc.). The method (and/or steps thereof) can be performed in a roll-to-roll process, in a batch process, and/or in a any suitable process.

Producing an electrode material S100 can function to make (e.g., produce, manufacture, synthesize, etc.) an active material for a cathode and/or anode. S100 can additionally or alternatively include making any suitable battery component (e.g., binder, conductive additive, separator, housing, electrolyte, etc.). In a first specific example, a cathode active material can be produced by forming oxides of lithium and/or any suitable metals (e.g., manganese for LMO; nickel, cobalt, and aluminium for NCA; manganese and nickel for LMNO; iron for LFP; etc.) such as by calcinating raw materials (and/or refining the raw materials to achieve a target metal composition); sintering the oxides; and optionally comminuting the sintered oxides. In a second specific example, an anode active (e.g., silicon particles thereof) material can be produced by reducing a silica precursor by: optionally purifying the silica precursor, exposing the silica to reaction modifiers (e.g., reducing agents such as magnesium, aluminium, etc.; thermal modifiers such as salt; etc.), optionally purifying the silica and reaction modifier mixture, optionally comminuting the silica (e.g., using a ball mill), reducing the silica to silicon (e.g., by heating the silica and reaction modifier to a reducing temperature), optionally purifying the silicon, optionally processing the silicon, and/or any suitable steps or processes. Examples of silica precursors include: waste silica (e.g., silica generated as a byproduct from another process such as waste, residual, etc. silica from a silicon purification process; silica produced during silicon production for solar, semiconductor, etc.; silica that would otherwise be disposed of; etc.), recycled silica (e.g., silica recycled or repurposed after a different use), pristine silica (e.g., newly manufactured silica), and/or any suitable silica starting material. The silica precursor is preferably silica fumes (e.g., fumed silica, fume silica, Cabosil fumed silica, aerosil fumed silica, etc.). However, the silica precursor can additionally or alternatively include sol-gel silica (e.g., silica prepared according to the Stöber method), diatoms, glass, quartz, sipernat silica, precipitated silica, silica gels, silica aerogels, decomposed silica gels, silica beads, silica sand, and/or any suitable silica material.

However, an electrode material (e.g., electrode active material) can be manufactured in any manner.

Producing an electrode S200 functions to manufacture (e.g., prepare, make, synthesize, form, etc.) an electrode. Each electrode (e.g., anode, cathode) can be processed and/or formed in the same or a different manner. The electrodes are preferably manufactured by casting a film of electrode material on a current collector. The electrode material is preferably cast from a suspension (e.g., solution, slurry, mixture, colloid, gel, etc.). Each electrode suspension can include: one or more solvent (e.g., water, organic solvent), binder (e.g., functional to bind electrode material together, to bind electrode material to the collector, etc. such as polymers), conductive material (e.g., conductive carbon additives), active material (e.g., anode active material, cathode active material, etc.), and/or any suitable additives or materials with any suitable concentration or relative concentration.

However, the electrode material can be cast from solid state, gas state, plasma state, liquid state, and/or any suitable state or mixture of materials. However, the electrodes can additionally or alternatively be grown, deposited, transferred to, and/or otherwise be formed on the collected. The electrodes can be produced in a roll-to-roll process, batch process, and/or using any suitable process. As an example, the electrodes can be produced using a coating machine (e.g., coater). However, any suitable tool(s) can be used to produce the electrodes.

As shown for example in FIG. 2 , S200 can include: receiving (e.g., forming) a suspension of electrode material S205 (e.g., from a manufacturer, from individual components, from materials as prepared in S100, etc.); optionally, processing the suspension S210 (e.g., dispersing the suspension, agitating the suspension, mixing the suspension, etc.); casting the electrode S220(e.g., by depositing the electrode material on an collector); optionally, drying the electrode S240; optionally, compacting the electrode S260 (e.g., densifying, calendering, etc.); optionally, sizing the electrode S280 (e.g., cutting the electrode); and/or any suitable steps.

Processing the suspension S210 can function to improve a homogeneity of the suspension, disperse materials that have settled within the suspension, and/or can otherwise function. The suspension can be processed in a fluidic chamber (e.g., microfluidic channel, microfluidic channel, etc.), vat (e.g., mixing basin), grinder, and/or in any suitable mixing vessel. The suspension can be mixed, for instance, using agitators, turbulators, blowers, fans, blades, paddles, stirrers (e.g., magnetic stirrers), shakers, speakers, grinders (e.g., ball mill), and/or any suitable components.

Components of the suspension can be added simultaneously and/or sequentially. For example, an anode slurry (e.g., slurry for making an anode) can be formed (e.g., processed) by simultaneously mixing anode active material, binder, and/or conductive material in a solvent (e.g., a mixture of water and ethanol). In a second example, an anode slurry can be formed by sequentially mixing anode active material in a solvent (e.g., a mixture of water and ethanol with a composition between 0% water and 100% water by mass, by volume, by stoichiometry, etc.), followed by mixing conductive material, followed by mixing binder. In a variation of the second example, the anode active material can be sequentially mixed for instance by first mixing silicon material in the solvent then graphite material (or vice versa). In a second variation (that can be combined with or separate from the first variation), the binder can be sequentially mixed in the suspension for instance by first mixing CMC in the suspension before mixing SBR in the suspension (or vice versa). However, the slurry can otherwise be formed or manufactured.

Casting the electrode functions to dispose electrode material on a collector. The electrode can be cast on a single side (e.g., broad face) of the collector and/or multiple sides (e.g., broad faces such as on two opposing sides) of the collector. The electrode suspension can be cast using drop-casting (e.g., with a doctor blade to achieve a target thickness), spin coating, slot-die coating, spray coating, brush coating, powder coating, printing, air knife coating, anilox coating, flexo coating, gap coating, gravue coating, dip coating, kiss coating, roller coating, extrusion coating (e.g., curtain coating, slide coating, slot die bead coating, etc.), and/or in any manner.

In some variants, a dry electrode casting process can be used where electrode material is deposited without dispersing the electrode material in a slurry.

The collector is preferably a foil but can have any suitable geometry. The collector is preferably aluminium (e.g., 5-15 µm thick aluminium foil) for the cathode and copper (e.g., 5-10 µm thick copper foil) for the anode, but can be made of any suitable materials. The same or different casting process can be used for each electrode.

Drying the electrode S240 functions to remove excess solvent from the cast electrode. Drying the cast electrode can additionally or alternatively function to partially densify the cast electrode, anneal the cast electrode (e.g., modify or change a phase of electrode materials), cyclize a polymer (e.g., cyclize PAN), crosslink one or more polymers, and/or can otherwise function.

The cast electrode (e.g., wet film, cast film, wet electrode film, wet cathode film, wet anode film, etc.) is preferably dried at a temperature below a carbonization temperature of a polymer (e.g., polymeric constituent of the electrode). For instance, the cast electrode can be dried at a temperature between about 0° C. and 200° C. However, in some variants drying can be performed at a temperature greater than 200° C. (e.g., to partially or fully carbonize polymer) and/or at a temperature less than 0° C.

In some variations, the cast electrode can be dried under vacuum, using dry air (e.g., air, gas, etc. with a relative humidity less than about 40%), and/or can be dried in any manner.

Densifying the electrode S360 preferably functions to increase a density of the electrode film (e.g., cast electrode, dried electrode, dried electrode film, dry electrode, etc.), which can improve the battery’s energy density, charge/discharge rates, wettability, cycle life, stability, durability, and/or other properties of the battery. Densifying the electrode can additionally or alternatively enhance a contact (e.g., electrical contact) between components of the electrode and/or can otherwise function (as shown for example by comparing the SEM images in FIG. 9A, FIG. 9B, and FIG. 9C).

Densifying the electrode can include compacting the electrode (e.g., using a compactor), calendering the electrode (e.g., using a calender), pressing the electrode (e.g., using a pressing mill), and/or otherwise densifying the electrode. The electrode is typical densified (e.g., a density of the electrode is increased by) between about 10% and 75% (e.g., 10%, 15%, 20%, 25%, 30%, 33%, 40%, 50%, 55%, 60%, 66%, 70%, 75%, values or ranges therebetween, etc.). For instance, an electrode can have a density of about 1 g/cm³ before densification and a density of about 1.3 to 1.5 g/cm³ after densification. Typically, too much densification will result in a silicon material that undergoes greater than a threshold and/or target external expansion (e.g., during lithiation which can result in degradation of a silicon anode resulting from delamination, particle degradation, repeated SEI layer formation and cracking, etc.). However, the electrode can be densified by greater than 75% (e.g., for applications where higher densities are acceptable) and/or less than 10%.

The electrode(s) can be densified at room temperature (e.g., about 20° C., 25° C., 30° C., etc.), at a temperature less than room temperature (e.g., about 0° C., about 10° C., <0° C., etc.), and/or at a temperature greater than room temperature (e.g., 40° C., 50° C., 75° C., 100° C., 150° C., 200° C., 300° C., 500° C., etc.).

Sizing the electrode S280 functions to modify a size and/or shape of the electrode and/or collector. S280 is typically performed after S260, but can be performed before and/or simultaneously with S260. The electrodes are preferably sized to approximately the same dimensions (e.g., have approximately the same area). The separator is preferably larger than the electrodes (e.g., larger in each direction orthogonal to parallel normals of broad faces of the electrodes such as by 1 mm, 2 mm, 3 mm, 5 mm, etc.; 1%, 2%, 5%, 10%, 20%, etc. of the electrode size; etc.). However, different electrodes can have different sizes. Similarly, the electrodes preferably fill the housing area (e.g., electrode area is about 80-95% of an internal area of the housing), which is beneficial for minimizing excess material and thereby increasing an energy density of the battery (e.g., by having less weight that does not contribute to the energy). However, the electrodes can fill any suitable portion of the housing interior.

The electrodes can be sized simultaneously and/or separately. Sizing the electrodes can include cutting the electrodes (e.g., using a cutter, die cutter, etc.), dinking the electrodes, tearing the electrodes, machining the electrodes, and/or any suitable steps or processes.

Assembling the battery S300 can function to attach the battery components together to form the battery. The battery can be assembled in line with (e.g., using a machine connected to) an electrode manufacturing machine and/or can be separate from the electrode manufacturing machine.

As shown for example in FIG. 5 , assembling the battery cell can include: contacting the electrodes S320 (e.g., across a separator), enclosing the electrodes in a housing S340 (e.g., inserting the electrodes into, placing the electrodes into, surrounding the electrodes with, etc. the housing), adding electrolyte to the electrodes S360 (e.g., within the housing), sealing the housing S380, and/or any suitable steps.

The electrodes can be contacted S320 using a roll-to-roll process (e.g., as shown for example in FIG. 3 ), by stacking the electrodes (e.g., before or after cutting to size using a die cutter or other cutter), and/or otherwise be contacted.

The housing can be sealed S380 using sealing tape, welding, crimping, vacuum sealing, and/or any suitable sealing mechanism. The housing can be a pouch (e.g., to form a pouch cell), cylindrical (e.g., to form a cylindrical cell), prismatic (e.g., to form a prismatic cell), and/or have any suitable format. In some variants (e.g., for liquid electrolyte, for a semifluid electrolyte, etc.), the housing can be partially sealed (e.g., along 3 sides for a 4-sided housing) to form a volume that can hold the electrolyte. After electrolyte is added S340 (e.g., poured in, aliquoted in, etc.), the housing can be fully sealed. However, the housing can be sealed in any manner.

The electrodes can be connected to tabs (e.g., such as an aluminium tab 111 for the cathode and a nickel tab 121 for the anode which can function to allow the cell to connect to a load, other battery cells to form a pack, etc.) that extend outside of the battery housing (as shown for example in FIG. 4A) and/or form a tabless battery (e.g., as shown for example in FIG. 4B such as to enable electrical contact to be made through the battery housing). However, the electrodes can otherwise be contacted.

The tabs for the electrodes can be on the same, adjacent, opposite, and/or any suitable sides of the battery and/or electrode. For example, as shown in FIG. 6A or FIG. 6B, the anode and cathode can have tabs on the same side of the battery. In another example, as shown in FIG. 6C, the anode and cathode can have tabs on opposite ends of the battery. However, the tabs can be arranged in any suitable portion of the battery and/or electrode (e.g., a plurality of sides).

The tabs can extend along approximately the full length of an electrode (e.g., as shown for example in FIG. 6B or FIG. 6C, length, width, diagonal dimension, diameter, etc.), along a predetermined extent of the electrode (e.g., as shown for example in FIG. 6A; such as 5%, 10%, 20%, 25%, 30%, 50%, 75%, values or ranges therebetween of the length, width, diagonal, diameter,, etc.; such as 1 mm ,2 mm, 5 mm, 10 mm, 15 mm, 20 mm, 25 mm, 30 mm, 50 mm, 100 mm, values or ranged therebetween, etc.; etc.), and/or for any suitable extent of the battery. Having a tab that extends along approximately the full length of an electrode can be beneficial for providing greater contact area (e.g., between the tab and the electrode).

In some variants (e.g., for pouch batteries), there can be a predetermined space (typically between 10-15 mm, but it can be larger or smaller) between the cell electrode and pouch end. In some embodiments, it can be beneficial to reduce (e.g., minimize) the predetermined space to save overall space of the battery, reduce a weight of the battery, and/or can otherwise be beneficial. The predetermined space can be reduced, for example, using sonic or ultrasonic welders we can minimize a metal weld down to 2 mm, using a plastic or polymer adhesive weld (or heat seal) can reduce an adhesive connection down to 2-3 mm (e.g., when we seal the cell after adding electrolyte). Typically, excess space (on the order of about 500 um -1 mm, but can be smaller than 500 µm or larger than 1 mm) of extra space is retained for the separator so it covers the edge of the electrodes. As a result, a battery can have a predetermined space down to 5 mm (or potentially smaller; as shown for example in FIG. 6 ). The adhering (e.g., welding) steps can be performed with one machine or a plurality of different machines. The adhering steps can be performed manually (e.g., by hand) or automatically (e.g., in a roll to roll process). In some variations, plastic welding on the edges of the battery can be used to reduce the excess foil on the sides (e.g., reducing the excess foil from 3-5 m down to 2 mm or less). Reducing the amount of excess foil and/or predetermined space can increase the Wh/L or Wh/kg of the cell (e.g., by less than 0.01%, 0.01%, 0.1%, 1%, 10%, values therebetween, etc.). Plastic welding can additionally be beneficial as it can be performed at low temperatures (e.g., room temperature, less than about 0° C., 10° C., 20° C., 50° C., 100° C., etc.) avoiding potential problems resulting from heating the battery (and/or constituents thereof).

Conditioning the battery S400 can function to modify (e.g., extend) a lifetime of the battery. For example, conditioning the battery can increase and/or decrease a charge state of the battery (e.g., state of charge) to protect the battery from battery aging conditions. For instance, when a temperature (or an expected temperature such as a temperature swing anticipated during shipping or transportation) is greater than a threshold temperature, the battery can be discharged to decrease aging of the battery. However, the battery can be conditioned in response to any suitable situation (e.g., environment, battery state, etc.) and/or the battery can not be conditioned.

Assessing a quality of the battery S500 functions to measure one or more battery property (particularly with a goal of ensuring batteries are consistent between instances of the method such as instances using different batches of electrode materials). Battery properties can include: electrode thickness, electrode capacity, energy density, lifetime, state of charge, state of health, state of power, voltage (e.g., open circuit voltage, instantaneous voltage, etc.), current (e.g., short circuit current, instantaneous current), temperature, impedance, thermodynamic properties (e.g., entropy, enthalpy, etc.), and/or any suitable properties. For example, assessing a quality of the battery(s) can include charging and/or discharging the battery at one or more charging rates while measuring the battery property (and/or measuring a property correlated with the battery property). However, the quality of the battery can otherwise be assessed.

Embodiments of the system and/or method can include every combination and permutation of the various system components and the various method processes, wherein one or more instances of the method and/or processes described herein can be performed asynchronously (e.g., sequentially), concurrently (e.g., in parallel), or in any other suitable order by and/or using one or more instances of the systems, elements, and/or entities described herein.

As a person skilled in the art will recognize from the previous detailed description and from the figures and claims, modifications and changes can be made to the preferred embodiments of the invention without departing from the scope of this invention defined in the following claims. 

We claim:
 1. A method for manufacturing a battery comprising: casting a wet anode film from a slurry, wherein the slurry comprises: at most about 15% binder by mass; at most about 20% conductive additive by mass; and between about 65% and 80% active material by mass, wherein the active material comprises: between about 30% and 50% silicon particles by mass, wherein the silicon particles comprise a vermiform morphology, wherein the silicon particles comprise nanoparticles with a characteristic size between about 2 and 150 nm, wherein the nanoparticles form silicon clusters with a characteristic cluster size between about 1 and 5 µm; and between about 50% and 70% graphite particles by mass; Drying the wet anode film to produce a dry anode film; Densifying the dry anode film to produce an anode; Contacting the anode and a cathode across a separator; Enclosing the anode, the cathode, and the separator in a housing; Adding electrolyte to the housing; and Sealing the housing.
 2. The method of claim 1, wherein the graphitic particles are spheroidal with a diameter between about 10 and 50 µm.
 3. The method of claim 1, wherein the dry anode film comprises about 70% active material by mass, 20% conductive material by mass, and 10% binder by mass.
 4. The method of claim 1, wherein the conductive additive comprises C6₅, and wherein the binder comprises polyacrylonitrile.
 5. The method of claim 1, wherein an N/P ratio of the anode to the cathode is between about 1 and 1.1.
 6. The method of claim 1, wherein the silicon particles are manufactured by reducing fumed silica.
 7. The method of claim 1, wherein the silicon clusters are agglomerated into agglomerates with a characteristic agglomerate size between about 2 and 50 µm.
 8. A method for forming a battery anode comprising: forming a slurry comprising: binder; conductive additive; and active material comprising silicon particles, wherein the silicon particles comprise an internal surface area between about 50 and 200 m²/g and an external surface area between about 10 and 20 m²/g; depositing the slurry on a current collector; drying the deposited slurry to form a deposited film; and compacting the deposited film to form the battery anode.
 9. The method of claim 8, wherein the silicon particles comprise between about 1 and 10% carbon by mass, between about 1 and 5% oxygen by mass, and between about 85 and about 98% silicon by mass.
 10. The method of claim 8, wherein the silicon particles comprise a nonspheroidal morphology.
 11. The method of claim 10, wherein the silicon particles comprise a polyhedral morphology.
 12. The method of claim 8, wherein the active material further comprises graphite.
 13. The method of claim 12, wherein the graphite comprises graphitic particles with a diameter between about 10 and 50 µm, wherein the silicon particles fill interstitial spaces between the graphitic particles within the battery anode.
 14. The method of claim 13, wherein compacting the deposited film comprises calendering the deposited film, wherein a density of the deposited film increases by between about 30% and 50% during calendering.
 15. The method of claim 13, wherein the deposited film comprises between about 70% and 90% active material by mass, between about 5% and 20% conductive material by mass, and between about 5 and 10% binder by mass.
 16. The method of claim 12, wherein the active material comprises between about 30% and 50% silicon particles by mass and between about 50% and 70% graphite.
 17. The method of claim 8, wherein the conductive additive comprises C6₅ black carbon, and wherein the binder comprises an approximately one to one mixture of carboxymethyl cellulose and styrene-butadiene rubber.
 18. The method of claim 8, wherein the silicon particles comprise a carbonaceous coating, wherein a surface area of the carbonaceous coating is between about 5 and 10 m2/g.
 19. The method of claim 7, wherein the silicon particles comprise an external volume expansion of at most about 15% during lithiation.
 20. The method of claim 7, wherein the silicon particles are manufactured from silica fumes that are reduced to silicon. 